Ultrasonic additive manufacturing of steel: Method, post-processing treatments and properties

Levy, Asaf; Miriyev, Aslan; Sridharan, Niyanth; Han, Tianyang; Tuval, Eran; Babu, S. S.; Dapino, Marcelo J.; Frage, N.

doi:10.1016/j.jmatprotec.2018.02.001

Cited by 64 publications

(45 citation statements)

References 20 publications

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“…Parabolic defects are associated with the medium or medium-to-high weld density levels, while point defects were observed with specimens with very high weld density levels [5]. Similar observations have been reported on Al6061-H18 [13] and 4130 steel/steel parts [21].…”

Section: Microstructuresupporting

confidence: 57%

“…It can be said from Table 1 that the selection of process parameters is dependent on the build material(s). For instance, a lower substrate temperature is selected when building SMA NiTi with aluminum [17], whereas a higher substrate temperature is selected for building similar materials such as 4130 steel [21]. As mentioned previously, the energy transferred to the workpiece is controlled by varying other process parameters as well.…”

Section: Temperature (°C)mentioning

confidence: 99%

“…With this attribute, bonding of dissimilar materials becomes feasible, and the properties of each building martial are retained. Similar and dissimilar builds via UAM such as Al-Al [10,[12][13][14][15], Al-Ti [16], Al-NiTi [17], Al-SiC [18,19], Al with embedded dielectric materials (inks used in printed electronics industry) [20], low carbon steel [21,22], and Alshape memory alloy (SMA) [23] have been reported in the literature so far.…”

Section: Introductionmentioning

confidence: 99%

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Power Ultrasonic Additive Manufacturing: Process Parameters, Microstructure, and Mechanical Properties

Gujba

Medraj

2020

Advances in Materials Science and Engineering

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Additive manufacturing (AM) for fabricating 3D metallic parts has recently received considerable attention. Among the emerging AM technologies is ultrasonic additive manufacturing (UAM) or ultrasonic consolidation (UC), which uses ultrasonic vibrations to bond similar or dissimilar materials to produce 3D builds. This technology has several competitive advantages over other AM technologies, which includes fabrication of dissimilar materials and complex shapes, higher deposition rate, and fabrication at lower temperatures, which results in no material transformation during processing. Although UAM process optimization and microstructure have been reported in the literature, there is still lack of standardized and satisfactory understanding of the mechanical properties of UAM builds. This could be attributed to structural defects associated with UAM processing. This article discusses the effects of UAM process parameters on the resulting microstructure and mechanical properties. Special attention is given to hardness, shear strength, tensile strength, fatigue, and creep measurements. Also, pull-out, push-out, and push-pin tests commonly employed to characterize bond quality and strength have been reviewed. Finally, current challenges and drawbacks of the process and potential applications have been addressed.

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Section: Microstructuresupporting

confidence: 57%

Section: Temperature (°C)mentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Power Ultrasonic Additive Manufacturing: Process Parameters, Microstructure, and Mechanical Properties

Gujba

Medraj

2020

Advances in Materials Science and Engineering

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“…UAM can produce good quality functional components but these components are sometimes prone to defects and delamination typical to UAM. Several studies focus on developing optimal process parameters for UAM and then eliminating defects through post-weld treatments [11,23,27,94,103,113,114,115,116]. To form a good bond, there must be enough power input into the ultrasonic weld while at the same time ensuring that already bonded interfaces are not pulled apart due to excessive vibration or power input [103].…”

Section: Sensitivity Analysis On the Inversion Scheme Indicates That mentioning

confidence: 99%

“…Both Type-1 and Type-2 defects in UAM components need to be eliminated either through improving the process or healed after manufacturing, so that UAM components can be used for structural applications [94,114]. Post-process heat treatment of UAM components was shown to be effective in increasing bond quality and reducing Type-1 defects, but heat treatment can't fix Type-2 defects.…”

Section: Sensitivity Analysis On the Inversion Scheme Indicates That mentioning

confidence: 99%

Ultrasonic nondestructive evaluation of metal additive manufacturing.

Nadimpalli¹

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Metal Additive Manufacturing (AM) is increasingly being used to make functional components. One of the barriers for AM components to become mainstream is the difficulty to certify them. AM components can have widely different properties based on process parameters. Improving an AM processes requires an understanding of processstructure-property correlations, which can be gathered in-situ and post-process through nondestructive and destructive methods. In this study, two metal AM processes were studied, the first is Ultrasonic Additive Manufacturing (UAM) and the second is Laser Powder Bed Fusion (L-PBF). The typical problems with UAM components are inter-layer and inter-track defects. To improve the UAM process, an in-situ quality evaluation technique was desired. Several NDE techniques were tested in a lab environment before ultrasonic NDE was chosen as a practical, robust, and cost-effective NDE tool. An in-situ monitoring setup was designed and built on an UAM system. NDE results showed interesting features that were simulated through analytic and finite element wave-propagation models. AM layers with defects were characterized as an intact layer and a finite interfacial stiffness spring. The spring stiffness vi coefficient is a quality parameter that was used to characterize AM layers through a modelbased inversion method. In-situ and post-process NDE provided an understanding of defect generation and propagation in UAM. A novel solid-state repair mechanism based on Friction Stir Processing (FSP) was proposed and demonstrated. The quality of L-PBF components depends on several factors including laser power, scan speed, hatch spacing, layer thickness, particle shape/size distribution and other build conditions. Developing process parameters for a new material is an expensive and complex optimization problem. Post-process ultrasonic NDE tests revealed that the model-based insitu quality monitoring developed for UAM is also applicable to L-PBF Additive Manufacturing. A similar NDE setup was designed and installed on an open-architecture L-PBF system. A layer-by-layer bond quality evaluation demonstrates the ability to detect good-quality bonds hidden behind poor-quality regions for Inconel 625 alloy. A costeffective, process parameter development methodology has been proposed and demonstrated. vii TABLE OF CONTENTS

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Additive Manufacturing Technologies and Post‐processing, Design Optimization, and Material Considerations for Reliable Printing

Singh¹,

Kumar²,

Jain³

2022

Nanotechnology‐Based Additive Manufacturing

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Ultrasonic additive manufacturing of steel: Method, post-processing treatments and properties

Cited by 64 publications

References 20 publications

Power Ultrasonic Additive Manufacturing: Process Parameters, Microstructure, and Mechanical Properties

Power Ultrasonic Additive Manufacturing: Process Parameters, Microstructure, and Mechanical Properties

Ultrasonic nondestructive evaluation of metal additive manufacturing.

Additive Manufacturing Technologies and Post‐processing, Design Optimization, and Material Considerations for Reliable Printing

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